Suction Muffler

ABSTRACT

Provide a suction muffler capable of enhancing the reliability of compressor, by preventing production of molten resin (slag) which solidifies in the suction muffler. Fit or put in contact with each other bonding portion ( 140 ) of a plurality of resin members ( 105 ), ( 120 ) formed in advance by injection molding, and bond bonding portion ( 140 ) with a resin belt formed with secondary injection molding. Because the bonding is made with the heat of the molten resin itself, it becomes possible to provide a suction muffler capable ( 101 ) of enhancing the reliability of compressor, by preventing production of slag due to pressing of bonding portion ( 140 ).

TECHNICAL FIELD

The present invention concerns a suction muffler for silencing simultaneously as it absorbs a gas, more specifically a suction muffler made of resin.

BACKGROUND ART

In recent years, there is a strong request for equipment with high energy efficiency, as hermetic compressor used for refrigerator, etc. from the viewpoint of prevention of global warming. It is already known that, generally, a suction muffler with low thermal conductivity made of synthetic resin, etc. is suitable as suction muffler to be used for hermetic compressor.

Conventionally, as suction muffler, a product bonded by ultrasonic welding by having a projection and a concavity respectively at the bonding portion of the mating molded resin piece is known (refer to Japanese Laid-Open Patent Publication No. S59-43917, for example).

FIG. 11 is a side exploded view of a conventional suction muffler. Suction muffler 1 is constructed by bonding first body 2 and second body 3 made of molded resin piece to each other, at edges 2 a, 3 a provided respectively. Flange 5 having convexity 4 is formed at edge 2 a, and flange 7 having concavity 6 is formed at edge 3 a, respectively. And, first body 2 and second body 3 are bonded to each other along bonding direction 11 a. Moreover, refrigerant gas is sucked into a non-illustrated compression chamber through communicating tube 14.

FIG. 12 is a sectional view of main part of the conventional suction muffler given in FIG. 11, and shows especially the state of bonding of flange 5 provided on the first body 2 side and flange 7 provided on the second body 3 side, made along bonding direction 12 a. As it was shown also in FIG. 11, concavity 6 is provided on the second body 3 side.

FIG. 13 is a drawing showing the manufacturing system of the conventional suction muffler. Suction muffler 1 shown in FIG. 11 used to be molded by positioning respective flanges 5, 7 of first body 2 and second body 3 at concavity 6 with convexity 4 and pressing them with horn 9 and frame 10 of press 8 indicated in FIG. 13 and, at the same time, by shaking them with application of ultrasonic vibrations while pressurizing flanges 5, 7 evenly, along bonding direction 13 a, and bonding first body 2 and second body 3 to each other by means of ultrasonic welding.

In the above-described conventional suction muffler made of resin, part of the resin is melted with ultrasonic wave and the bonded portion of the parts is pressed at the same time. For that reason, in case the bonding accuracy at the bonded portion is not so good, a problem is produced that part of the molten resin jumps out through the gap at the bonded portion, sticking to the inside of the suction muffler and solidifying there. Such part of molten resin which solidified inside the suction muffler is generally called “slag.”

Such slag produced inside the suction muffler is difficult to check for production and remove in advance, because the production of slag takes place after the bonding of resin members. Should the slag remaining inside the suction muffler be separated, it is sucked into the compressor together with the refrigerant, to present a problem of narrowing the sliding portion of the compressor, eventually leading to a stop of compressor.

DISCLOSURE OF THE INVENTION

The present invention provides a suction muffler capable of enhancing the reliability of compressor.

The suction muffler according to the present invention has a plurality of bonding portions made of resin members either fit to each other or put in contact with each other, and bonded by means of a resin belt formed with secondary injection molding. The surface of the bonding portion of the resin members molded in advance are bonded to each other by utilizing the heat of the molten resin injected with secondary injection molding. To that purpose, the pressing of the bonding portions and the shaking given to the suction muffler are controlled to control the production of so-called slag. Such suction muffler according to the present invention can eliminate the step of pressing to the bonding portions, in the case where a suction muffler constructed with a plurality of resin members is bonded, thus enabling to provide a suction muffler capable of enhancing the reliability of compressor, by preventing production of slag.

The concrete construction of the suction muffler according to the present invention consists in either fitting or putting in contact with each other the bonding portion of a plurality of resin members formed in advance by injection molding. At the same time, the bonding portion is bonded with a resin belt formed with secondary injection molding. Since the bonding of molten resin is made with heat only, this enables to prevent production of slag due to pressing of bonding portions, and to thus provide a suction muffler capable of enhancing the reliability of compressor.

Moreover, the suction muffler according to the present invention has the shape of its bonding face at the fitting portion bent, in the cross section of the bonding portion. Such construction increases the inflow resistance, and this makes it possible to prevent the problem of molten resin flowing into the suction muffler, even in case of inflow of molten resin in the bonding face. This enables to enhance the reliability of compressor.

Furthermore, the suction muffler according to the present invention forms fine projections at the outer circumference of the bonding portion to be bonded by secondary injection molding. A plurality of fine projections provided at the outer circumference of the bonding portion enable to increase the heat receiving surface area on the resin member side. This makes it possible to heat either the fine projections or fine ribs in a comparatively short time, thus enabling to form a suction muffler with bonded resin members. Such construction enables to provide a suction muffler of higher productivity.

Still more, the suction muffler according to the present invention forms a flange which may be realized also by integration in the state in which the contacts of the bonding portion to be bonded by secondary injection molding are in contact with each other. After the bonding, by providing flanges across the bonding face, it becomes possible to engage the resin belt and the resin members formed by secondary injection molding with each other by means of the flanges, in addition to the reactive force applied to the melting portion of the resin belt and the resin members formed by secondary injection molding, even in the case where an outer force is applied in the direction in which the resin members forming the suction muffler are removed. Such construction enables to provide a suction muffler capable of further improving the reliability of compressor.

Yet more, the suction muffler according to the present invention has a tail pipe formed separately inside the suction muffler, and a through hole communicating with the tail pipe at the bonding portion. In addition, the resin members and the tail pipe are combined by means of secondary injection molding. By bonding the tail pipe and the resin members forming the suction muffler at a time, it becomes possible to omit the facilities and working process for bonding the tail pipe, thus enabling to provide an inexpensive suction muffler.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the suction muffler in preferred embodiment 1 of the present invention.

FIG. 2A is a side exploded view of the suction muffler in preferred embodiment 1 of the present invention.

FIG. 2B is a side exploded view of the suction muffler in preferred embodiment 1 of the present invention.

FIG. 3A is an expanded view of the portion A indicated in FIG. 2, in preferred embodiment 1 of the present invention.

FIG. 3B is an expanded view of the portion B indicated in FIG. 2, in preferred embodiment 1 of the present invention.

FIG. 4A is a disassembling-assembling drawing of the suction muffler in preferred embodiment 1 of the present invention.

FIG. 4B is a disassembling-assembling drawing of the suction muffler in preferred embodiment 1 of the present invention.

FIG. 4C is a disassembling-assembling drawing of the suction muffler in preferred embodiment 1 of the present invention.

FIG. 5 is a side exploded view of the suction muffler in preferred embodiment 2 of the present invention.

FIG. 6A is an expanded view of the portion C indicated in FIG. 5, in preferred embodiment 2 of the present invention.

FIG. 6B is an expanded view of the portion D indicated in FIG. 5, in preferred embodiment 2 of the present invention.

FIG. 7A is a disassembling-assembling drawing of the suction muffler in preferred embodiment 2 of the present invention.

FIG. 7B is a disassembling-assembling drawing of the suction muffler in preferred embodiment 2 of the present invention.

FIG. 7C is a disassembling-assembling drawing of the suction muffler in preferred embodiment 2 of the present invention.

FIG. 8 is a perspective disassembling schematic diagram of the suction muffler in preferred embodiment 3 of the present invention.

FIG. 9 is a side exploded view of the suction muffler in preferred embodiment 3 of the present invention.

FIG. 10A is a disassembling-assembling drawing of the suction muffler in preferred embodiment 3 of the present invention.

FIG. 10B is a disassembling-assembling drawing of the suction muffler in preferred embodiment 3 of the present invention.

FIG. 10C is a disassembling-assembling drawing of the suction muffler in preferred embodiment 3 of the present invention.

FIG. 11 is a side exploded view of a conventional suction muffler.

FIG. 12 is a sectional view of main part of the conventional suction muffler.

FIG. 13 is a schematic diagram of an ultrasonic welding apparatus for the conventional suction muffler.

DESCRIPTION OF REFERENCE OF NUMERALS AND SIGNS

-   -   101, 201, 301: Suction muffler     -   105, 305, 120, 320: Resin member     -   107, 125: Fine projection     -   140, 240, 340: Bonding portion     -   144: Bonding portion     -   160 a, 260 a, 360 a: Resin belt     -   206, 226: Contact     -   247: Flange     -   330: Tail pipe     -   392: Through hole

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Preferred embodiments of the suction muffler according to the present invention will be described below with reference to drawings.

Preferred Embodiment 1

FIG. 1 is a perspective view of the suction muffler in preferred embodiment 1 of the present invention. FIG. 2A, FIG. 2B are side exploded views of the suction muffler in preferred embodiment 1 of the present invention. FIG. 3A is an expanded view of the portion A indicated in FIG. 2, in preferred embodiment 1, while FIG. 3B is an expanded view of the portion B indicated in FIG. 2, in preferred embodiment 1. FIG. 4A, FIG. 4B, FIG. 4C are disassembling-assembling drawings of the suction muffler in preferred embodiment 1.

In FIG. 1, the outside of suction muffler 101 is filled with gas such as refrigerant, etc. Suction muffler 101 comprises suction port 110 for sucking the gas, and hollow portion 135 for once releasing the sucked gas. Moreover, it also comprises communicating tube 108 for connecting between hollow portion 135 and suction port 110, communicating tube 115 for leading the gas sucked into hollow portion 135 to the cylinder of a reciprocating compressor, etc., and tail pipe 130 formed separately and connected to communicating tube 115 for extending the length of pipe inside the suction muffler.

Hollow portion 135 is formed by bonding resin member 105 provided with communicating tube 115 and communicating tube 108, and resin member 120 provided with fastening portion 150 for fixing the position of tail pipe 130 with bonding portion 140.

FIG. 2A is a side exploded view of the suction muffler in preferred embodiment 1 of the present invention, showing the state as seen from the direction X1 indicated in FIG. 1. FIG. 2A shows projection 123, fine projection 125, and bonding portion 146. Projection 123, provided on the circumference of bonding portion 146 of resin member 120, has fine projection 125.

FIG. 2B shows the state as seen from the direction X2 indicated in FIG. 1. Guide 103, provided on the circumference of bonding portion 143 of resin member 105, bends the bonding face in the shape of the character L, and comprises a plurality of fine projections 107. And the connecting portion between guide 103 and outer wall 109 is formed with a difference of level.

Explanation will be given below, on the bonding method of a suction muffler constructed as above. Resin member 105 and resin member 120 are fit to each other, after being formed as separate pieces respectively, at bonding portion 143 and bonding portion 146 indicated in FIG. 2A and FIG. 2B. After the fitting of resin member 105 and resin member 120, suction muffler 101 is fixed in the metallic mold again, and cavity 142 is formed along bonding portion 140, with metallic mold 170 and the resin forming bonding portion 140. After suction muffler 101 is fixed with metallic mold 170, molten resin 160 is injected into cavity 142.

FIG. 3A is an expanded view of the portion A indicated in FIG. 2A, while FIG. 3B is an expanded view of the portion B indicated in FIG. 2B. In FIG. 3A, projection 123 and fine projections 125 are indicated, as shown in FIG. 2A. Moreover, FIG. 3B indicates the state in which a plurality of fine projections 107 are provided on guide 103, and the connecting portion between guide 103 and outer wall 109 is formed with a difference of level.

FIG. 4 is a disassembling-assembling drawing of the suction muffler in preferred embodiment 1. Injected molten resin 160 fills cavity 142, and solidifies while melting resin member 105 and resin member 120 together. For that reason, resin member 105 and resin member 120 are bonded integrally simultaneously as resin belt 160 a is formed.

In preferred embodiment 1, the surface of the bonding portion is molten only with the heat of molten resin 160 itself for bonding, and this enables to eliminate the defect of shaking the suction muffler while pressing the bonding portion during the melting. For that reason, it becomes possible to provide a suction muffler capable of enhancing the reliability of compressor, by preventing production of slag in the hollow portion.

Furthermore, since fitting portion 144 is bent about in the shape of the character L, it is possible to prevent inflow of molten resin 160 into the hollow portion, with an increased resistance, even in case molten resin 160 flew into fitting portion 144, thus enabling to provide a suction muffler capable of further enhancing the reliability of compressor.

In addition, because the bonding portion has fine projection 125, the surface area subject to heat from molten resin 160 increases and is heated with the heat of molten resin 160 up to a temperature equal to it in a short time, it becomes possible to form a suction muffler by bonding the resin members to each other, in the state integrated with resin belt 160 a accurately, thus enabling to provide a suction muffler with a still higher productivity.

By the way, the section of fitting portion 144 may take the shape of the character U instead of L and, in either case, it provides similar effects if the section is not in a simple linear shape. Although the character U is formed with straight portions and a curve, the shape of the character U as meant in the present invention includes a character U the curved part of which is formed with a straight line or a character U the straight part of which is formed with a curve. Resin member 105 forming cavity 142 and the section formed by resin member 120 may also take a shape other than character U. Moreover, fine projections 107, 125 provided on guide 103 and projection 123 may be fine grooves, and the grooves or fine projections are all right if they are provided in the direction which takes account of the extraction from mold of the members forming the suction muffler.

Preferred Embodiment 2

FIG. 5 is a side exploded view of the suction muffler in preferred embodiment 2 of the present invention. FIG. 6A is an expanded view of the portion C indicated in FIG. 5, in preferred embodiment 2. FIG. 6B is an expanded view of the portion D indicated in FIG. 5, in preferred embodiment 2. FIG. 7A to FIG. 7C are disassembling-assembling drawings of the suction muffler in preferred embodiment 2.

In FIG. 5, suction muffler 201 comprises suction port 210 for sucking the gas, and hollow portion 235 for once releasing the sucked gas. Moreover, it also comprises communicating tube 208 for connecting between hollow portion 235 and suction port 210, communicating tube 215 for leading the gas sucked into hollow portion 235 to the cylinder of a reciprocating compressor, etc., and tail pipe 230 formed separately and connected to communicating tube 215 for extending the length of pipe inside the suction muffler.

Hollow portion 235 is formed by bonding resin member 205 provided with communicating tube 215 and communicating tube 208, and resin member 220 provided with fastening portion 250 for fixing the position of tail pipe 230 to each other with bonding portion 240.

FIG. 6A is an expanded view of the portion C indicated in FIG. 5, and guide 223 forming the shape of the character L along bonding portion 240 and contact 226 having fitting face 229 as side face are provided circumferentially.

FIG. 6B is an expanded view of the portion D indicated in FIG. 5. Guide 203 having the shape of the character L is provided circumferentially along bonding portion 240, and contact 206 having fitting face 207 as side face is also provided circumferentially.

FIG. 7A to FIG. 7C are bonding process charts for explaining the bonding method of the suction muffler in preferred embodiment 2.

Firstly, as shown in FIG. 7A, resin member 205 and resin member 220 are fit to each other, after being formed as separate pieces respectively, at fitting face 207 and fitting face 229. After the fitting of resin member 205 and resin member 220, suction muffler 201 (see FIG. 5) is fixed in the metallic mold again, and cavity 242 is formed along bonding portion 240, with metallic mold 270 and the resin forming bonding portion 240. Inside cavity 242, flange 247 is formed in convex shape by contact 206 and contact 226.

After suction muffler 201 is fixed with metallic mold 270, molten resin 260 is injected into cavity 242. Injected molten resin 260 fills cavity 242, and solidifies while melting resin member 205 and resin member 220 together. For that reason, resin member 205 and resin member 220 are bonded integrally simultaneously as resin belt 260 a is formed.

In preferred embodiment 2, flange 247 is provided inside cavity 242 in which fitting face 207 and fitting face 229 are interposed. Such construction enables to engage resin belt 260 a and resin members 205, 220 formed by secondary injection molding with each other by means of flange 247, in addition to the reactive force applied to the melting portion of resin belt 260 a and resin members 205, 220 formed by secondary injection molding. This makes it possible to provide a suction muffler with high bonding strength capable of further improving the reliability of compressor.

Moreover, the shape of contact formed inside cavity 242 may be other than the shape of the character U. Furthermore, even without providing guide 203 and guide 223, it is possible to provide a suction muffler with high bonding strength capable of further improving the reliability of compressor equally, by wrapping flange 247 with the metallic mold and injecting molten rein along bonding portion 240.

Preferred Embodiment 3

FIG. 8 is a perspective disassembling schematic diagram of suction muffler 301. Concavity 390 is formed in resin member 305 of suction muffler 301. Moreover, concavity 385 and insert port 302 are also formed in resin member 305. Furthermore, tail pipe 330 is provided with inserting portion 332 for insertion into insert port 302, and projection 334 in columnar shape. Fitting line 336 indicates that inserting portion 332 is fit into insert port 302.

FIG. 9 is a side exploded view of the suction muffler in preferred embodiment 3. Suction muffler 301 comprises suction port 310 for sucking the gas such as refrigerant, etc., and hollow portion 335 for once releasing the sucked gas. It also comprises communicating tube 308 for connecting between hollow portion 335 and suction port 310, communicating tube 315 for leading the gas sucked into hollow portion 335 to the cylinder of a reciprocating compressor, etc., and tail pipe 330 formed separately and connected to communicating tube 315 for extending the length of pipe inside the suction muffler. Tail pipe 330 is provided with inserting portion 332 for insertion into insert port 302 (see FIG. 8) of communicating tube 315, and projection 334 in columnar shape. Fitting line 336 indicates that inserting portion 332 is fit into insert port 302.

Hollow portion 335 is formed by bonding resin member 305 provided with communicating tube 308 and communicating tube 315, and resin member 320 provided with fastening portion 340. Resin member 305 is provided with insert port 302 for inserting tail pipe 330 into communicating tube 315. Bonding portion 343 comprises guide 303, while guide 303 is provided with concavity 385 (see FIG. 8), forming a semi-circular arc coaxially with projection 334, for fitting projection 334.

Resin member 320 is provided with bonding portion 346, and L-shaped guide 323 is provided circumferentially on bonding portion 346. Guide 323 has concavity 390 (see FIG. 8) forming a pair with concavity 385. When concavity 385 and concavity 390 are fit to each other, they form through hole 392 to be described later for connecting the inside of the suction muffler with the outside.

FIG. 10A to FIG. 10C are disassembling-assembling drawings of the suction muffler in preferred embodiment 3. The bonding method of the suction muffler will be explained below, with reference to FIG. 9 and FIG. 10A to FIG. 10C.

In the first place, simultaneously as inserting portion 332 of tail pipe 330 is fit into insert port 302 of resin member 305, projection 334 of tail pipe 330 is fit into concavity 385. After the insertion of tail pipe 330, bonding portion 346 of resin member 320 is fit to bonding portion 343 of resin member 305. At the same time, projection 334 is fit by concavity 385 and concavity 390.

After the fitting of resin member 305, resin member 320 and tail pipe 330, concavity 342 is formed with the resin forming metallic mold 370 and bonding portion 340, and part of projection 334 protrudes to the inside of concavity 342.

After suction muffler 301 is fixed with metallic mold 370, molten resin 360 is injected into concavity 342. Injected molten resin 360 melts the resin of resin member 305 and the resin of resin member 320, which form concavity 342. At the same time, the resin of projection 334 of tail pipe 330 protruding to the inside of concavity 342 also melts and solidifies, enabling to bond resin member 305, resin member 320 and tail pipe 330 at a time, simultaneously with the formation of resin belt 360 a.

According to preferred embodiment 3, projection 334 of tail pipe 330 is bonded simultaneously as the bonding of resin member 305 and resin member 320, which form hollow portion 335. For that reason, there is no more need of fixing resin member 305 and tail pipe 330 to each other in a separate process. This makes it possible to omit the working process and facilities for simply fixing tail pipe 330, thus enabling to provide an inexpensive suction muffler.

As means for fixing tail pipe 330, resin member 305 and resin member 320, it is all right if only the molten resin is in contact with part of tail pipe 330, even if part of tail pipe 330 does not protrude into the cavity.

INDUSTRIAL APPLICABILITY

As described above, the suction muffler according to the present invention is highly reliable and can be realized at a low cost. For that reason, it can be applied to refrigerator of household use and other articles using refrigeration cycle such as dehumidifier, showcase, vending machine, etc. and has high industrial applicability. 

1. A suction muffler formed by either fitting or putting in contact with each other the bonding portion of a plurality of resin members formed in advance by injection molding, and bonding the bonding portion with a resin belt formed with secondary injection molding.
 2. A suction muffler according to claim 1, wherein the shape of bonded face of the fitting portion is bent, at the cross section of the bonding portion.
 3. A suction muffler according to claim 1, wherein a plurality of projections or ribs are provided on the outer circumference of the bonding portion.
 4. A suction muffler according to claim 1, wherein a flange is formed in the state in contact with the contacts of the bonding portion.
 5. A suction muffler according to claim 1, wherein a tail pipe is formed separately inside the suction muffler, a through hole communicating with the tail pipe is provided at the bonding portion, and the resin member and the tail pipe are bonded to each other with the resin belt. 